Hydrophilic and hydrophobic silane surface modification of abrasive grains

ABSTRACT

A surface-modified abrasive grain includes an abrasive grain as a substrate, and a film on the abrasive grain that includes a relatively hydrophilic silane component and a relatively hydrophobic silane component. The film can be a single film layer or multiple film layers, wherein a film layer most proximal to the abrasive grain has a predominately hydrophilic silane component, and a film layer more distal to the abrasive grain includes predominately a relatively hydrophobic silane component. Coated abrasive products and bonded abrasive products include the surface-modified abrasive grains.

RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No.61/124,618, filed on Apr. 18, 2008. The entire teachings of the aboveapplication are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Wet grinding operations, defined by grinding processes using water-basedcoolant systems, have been found to be hampered with shorter life of theabrasive product as compared with dry grinding applications. Thisphenomenon typically has been addressed by addition of sealant in theformulation of make resin employed in the abrasive. Chemicals added tothe make resin to counteract the effect of water generally includehydrophobic molecules that increase hydrophobicity of the make resin tothereby reduce the intake of water, to retard swelling of the resinsystem consequent to deterioration of mechanical properties, and toretard abrasive loss. Examples of hydrophobic molecules typically aresiloxanes and organo-functional silanes (hereinafter referred to as“silanes”) or other organic molecules that have hydrophobic moieties,such as vinyl bonds, and sulfur or fluorine atoms in the organicmolecule. However, inclusion of hydrophobic components in the make resinoften does not protect abrasive particles upon contact with water,thereby permitting water over extended use periods to migrate alongabrasive particles until the abrasive tool fails. In the case of coatedabrasive products, contact of the backing material with water employedas a coolant can cause separation of the abrasive and make coat from thebacking material.

In one alternative, abrasive particles are first treated by applying acoating of a silane. Hydrolysis of the silane at a surface of anabrasive particle can cause formation of covalent bonds, particularlywhere the abrasive particle is a metal. However, formation of ahydrophilic coating on grains can reduce the strength with whichparticles are held in place by the make coat, particularly where themake coat includes a hydrophobic component, such as a hydrophobic silanecomponent.

Therefore, a need exists for abrasive particles, coated abrasiveproducts and other grinding tools, such as bonded abrasive tools, thatovercome or minimize the above-referenced problems.

SUMMARY OF THE INVENTION

The invention generally is directed to surface-modified abrasive grains,coated abrasive products, bonded abrasive products, and methods ofmanufacturing and using the grains and abrasive products. In oneembodiment, the invention is a surface-modified abrasive grain thatincludes an abrasive grain substrate and a film on the abrasive grainthat includes a relatively hydrophilic silane component and a relativelyhydrophobic silane component. The relatively hydrophilic silanecomponent, in one embodiment, can be one member selected from the groupconsisting of amines, diamines, triamines, azine, azol, ureido,isocyanate, alkoxy, acetoxy, oximino, chloro, morpholinyl andpiperazinyl silanes, and the relatively hydrophobic silane can be onemember selected from the group consisting of vinyl silanes, methacrylatesilanes, sulfur silanes, mercapto silanes, epoxy silanes and phenylsilanes. The film can be either a single layer that includes acombination of relatively hydrophilic and relatively hydrophobic silanecomponents. In this embodiment, polymers of the relatively hydrophilicand hydrophobic components can be distinct polymers, or co-polymers ofthe relatively hydrophilic and relatively hydrophobic silane components.Typically, the abrasive grain substrate includes at least one memberselected from the group consisting of aluminum oxide, silicon carbide,fused ceramics, alloy abrasives, sol-gels, ceramic grains and superabrasives.

In another specific embodiment, the coating of the abrasive particlesincludes two layers, the first of which is most proximate to theabrasive particle and includes at least one relatively hydrophilicsilane component. The second layer is distal, and generally applied overthe first layer. The second layer includes at least one silane componentthat is hydrophobic relative to the silane component of the first layer.

In another embodiment, the invention is a coated abrasive product thatincludes surface-modified abrasive grains of the invention. In stillanother embodiment, the invention is bonded abrasive product employingthe surface-modified abrasive particles of the invention.

A surface-modified abrasive grain of the invention can be formed, in oneembodiment, by combining a relatively hydrophilic and relativelyhydrophobic silane components to form a mixture. The mixture is thencombined with a carrier that includes water to form a silane solution.At least a portion of the silane component is hydrolyzed to form ahydrolyzed solution, which is then blended with an abrasive graincomponent to thereby form the surface-modified abrasive grain.

A method of forming a coated abrasive product of the invention includescombining the surface-modified abrasive grains of the invention with aresin and then applying the combined surface-modified abrasive grainsand resin to a backing. The resin is then cured, thereby forming thecoated abrasive product.

A method of making a bonded abrasive product of the invention includescombining surface-modified abrasive grains of the invention with a resinor a vitreous glass bond along with a binder. The resulting greencompound is molded or formed into the desired shape and subsequentlythermally cured or fired to result in the final product.

Other embodiments of the invention include grinding or cutting aworkpiece employing a coated or bonded abrasive product of theinvention.

The invention has many advantages. For example, the relativelyhydrophilic silane component of the film is believed to effectively seepinto most types of abrasive particles, thereby facilitating wetting ofthe component with a sealant that includes the relatively hydrophilicsilane component. In addition, it is believed that the same film formscovalent bonds that bind the sealant tightly to the particle. Inaddition, the relative hydrophobic silane component of the film caneither be blended with the relatively hydrophilic silane component orapplied as a separate film that binds tightly to most make coat resins,particularly those that include a hydrophobic silane component apartfrom that of the film of the abrasive grain. As a result, the film ofthe abrasive grain does not separate easily from either the particle orfrom the make coat upon exposure to water, thereby significantlyreducing penetration of the abrasive product by water coolants employedduring grinding or cutting. Material Removal Rate (MRR) and CumulativeMaterial Retention (CMR) are significantly increased as a result.“Surface finish,” or “Ra,” of a work piece also is significantlyimproved relative to that produced by use of abrasive products which donot employ a silane treatment or film of the invention. Further, theusable life of abrasive products of the invention can be significantlyextended beyond that which would be expected of abrasive products thatdo not employ the surface-modified abrasive grains of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross section of a coated abrasive product of the inventionemploying the surface-modified abrasive particles of FIG. 1.

FIG. 2 is an example of a bonded abrasive tool of the inventionemploying the abrasive particles of FIG. 1.

FIG. 3A is a table of comparative test results obtained at 30 lbs on aLoesser centerless grinder employing an embodiment of the invention.

FIG. 3B is a plot of MRR presented in the table of FIG. 3A.

FIG. 3C is a plot of surface finish, Ra, presented in the table of FIG.3A.

FIG. 3D is a plot of abrasive loss (%) presented in the table of FIG.3A.

FIG. 4A is a table of comparative test results obtained at 50 lbs as aLoesser centerless grinder employing an embodiment of the invention.

FIG. 4B is a plot of MRR presented in the table of FIG. 4A.

FIG. 4C is a plot of surface finish, Ra, presented in the table of FIG.4A.

FIG. 4D is a plot of abrasive loss (%) presented in the table of FIG.4A.

FIG. 5A is a table summarizing the results presented in the tables ofFIGS. 3A-4A.

FIG. 5B is a histograph of the results presented in FIG. 5A.

FIG. 6 is a photograph of the embodiment of the invention and that ofthe comparative product employed in generating the test results of thetables presented in FIGS. 3A-3D, 4A-4D and 5A-5B.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing will be apparent from the following more particulardescription of exampled embodiments of the invention, as illustrated bythe accompanied drawings in which like reference characters refer to thesame parts throughout the different views. The drawings are notnecessarily to scale, with emphasis instead being placed on illustratedembodiments of the present invention.

The invention generally is directed to surface-modified abrasive grains,and to coated abrasive products and bonded abrasive products employingthe surface-modified abrasive grains. The surface-modified abrasivegrains of the invention include an abrasive grain substrate and a filmon the abrasive grain that includes a relatively hydrophilic silanecomponent and a relatively hydrophobic silane component. The inventionis also directed to methods of making the surface-modified abrasivegrains of the invention, as well as to coated and bonded abrasiveproducts employing the surface-modified abrasive grains, and to methodsof making and using coated and bonded abrasive products of theinvention.

The term “relatively hydrophilic silane component,” as that term isdefined herein, means a silane monomer, oligomer or polymer, or to amonomeric repeating unit of an oligomer or polymer that exhibits moreaffinity for water than does another monomer, oligomer or polymer, orrepeating monomeric silane component with which the relativelyhydrophilic silane component has been combined. Examples of relativelyhydrophilic silane components include amino silanes, amino silanes,ureido silanes, isocyanate silanes, oximino silanes and chloro silanes.Specific examples of particularly suitable relatively hydrophilic silanecomponents include 3-aminopropyltriethoxy silane,3-Aminopropyltriethoxysilane, Bis[(3-Triethoxysilyl)Propyl]Amine,3-Aminopropyltrimethoxysilane, 3-Aminopropylmethyldiethoxysilane,3-Aminopropylmethyldimethoxysilane,Aminoethylaminopropyltrimethoxysilane,Aminoethylaminopropyltriethoxysilane,Aminoethylaminopropylmethyldimethoxysilane,Aminoethylaminopropylmethyldiethoxysilane,Aminoethylaminomethyltriethoxysilane,Aminoethylaminomethylmethyldiethoxysilane,Diethylenetriaminopropyltrimethoxysilane,Diethylenetriaminopropyltriethoxysialne,Diethylenetriaminopropylmethyldimethoxysilane,Diethylenetriaminopropylmethyldiethoxysilane,Diethylenetriaminomethylmethyldiethoxysilane,Diethylaminomethyltriethoxysilane,Diethylaminomethylmethyldiethoxysilane,Diethylaminomethyltrimethoxysilane, Diethylaminopropyltrimethoxysilane,Diethylaminopropylmethyldimethoxysilane,Diethylaminopropylmethyldiethoxysilane,N—(N-Butyl)-3-Aminopropyltrimethoxysilane,(N-Phenylamino)Methyltrimethoxysilane,(N-Phenylamino)Methyltriethoxysilane,(N-Phenylamino)Methylmethyldimethoxysilane,(N-Phenylamino)Methylmethyldiethoxysilane,3-(N-Phenylamino)Propyltrimethoxysilane,3-(N-Phenylamino)Propyltriethoxysilane,3-(N-Phenylamino)Propylmethyldimethoxysilane,3-(N-Phenylamino)Propylmethyldiethoxysilane,piperazinylpropylmethyldimethoxysilane,piperazinylpropylmethyldiethoxysilane,piperazinylmethylmethyldiethoxysilane,Morpholinylpropyltrimethoxysilane, Morpholinylpropyltriethoxysilane,Morpholinylpropylmethyldimethoxysilane,Morpholinylpropylmethyldiethoxysilane,Morpholinylmethyltrimethoxysilane,Morpholinylmethylmethyldiethoxysilane,Aminohexylaminomethyltrimethoxysilane,Hexanediaminomethyltriethoxysilane,Aminohexylaminomethyltrimethoxysilane,Octanoylaminopropyltriethoxysilane,Cyclohexylaminopropyltrimethoxysilane,Cyclohexylaminopropyltriethoxysilane,Cyclohexylaminopropylmethyldimethoxysilane,Cyclohexylaminopropylmethyldiethoxysilane,3-ureidopropyltrimethoxysilane, 3-ureidopropyltriethoxysilane,3-isocyanatepropyltrimethoxysilane, 3-isocyanatepropyltriethoxysilane,Trimethoxysilane, Triethoxysilane, Methyldimethoxysilane,Methyldiethoxysilane, Methyltrimethoxysilane, Methyltriethoxysilane,Methyltripropoxysilane, Methyltributoxysilane,Methyltris(Tert-Butylperoxy)Silane, Dimethylethoxysilane,Dimethyldimethoxysilane, Dimethyldiethoxysilane, Propyltrimethoxysilane,N-Butyltrimethoxysilane, N-Butyltriethoxysilane,1-Butyltrimethoxysilane, 1-Butyltriethoxysilane, Allyltriethoxysilane,Dodecyltrimethoxysilane, Dodecylmethyldimethoxysilane,Octodecyltrimethoxysilane, Octodecyltriethoxysilane,Octodecylmethyldimethoxysilane, N-Octyltrimethoxysilane,N-Octyltriethoxysilane, Octylmethyldiethoxysilane,Cyclohexyltriethoxysilane, Tetraacetoxysilane, Ethyltriacetoxysilane,Methyltriacetoxysilane, Dimethyldiacetoxysilane,Di-Tertbutoxy-Diacetoxysilane, Phenyltris(Methylethylketoxime)Silane,Tetra(Methylisobutylketoxime)Silane,Trimethyl(Methylethylketoxime)Silane,Dimethyldi(Methylethylketoxime)Silane,Methyltris(Methylisobutylketoxime)Silane, Methyltris(Acetoxime)Silane,Methyltris(Methylethylketoxime)Silane,Vinyltris(Methylisobutylketoxime)Silane,Methylvinyldi(Cyclohexanoneoxime)Silane,Methylvinyldi(Methylethylketoxime)Silane,Vinyltris(Methylethylketoxime)Silane.

As defined herein, the term “relatively hydrophobic silane component,”means monomer, oligomeric and polymeric compounds that include moietiesthat cause the monomer, oligomer or polymer to have an affinity forwater that is less than that of another silane component with which itis combined. Examples of classes of relatively hydrophobic silanecomponents include vinyl silanes, methacrylate silanes, sulfur silanes,mercapto silanes, epoxy silanes, phenyl silanes. Examples of particularrelatively hydrophobic silane components includeγ-methacryloxypropyltrimethoxy silane, Vinyltrimethoxysilane,Vinyltriethoxysilane, Vinyltris(2-Methoxyethoxy)Silane,Vinyltrisisopropoxysilane, Vinyltris(Tert-Butylperoxy)Silane,Vinyldimethylethoxysilane, Vinylmethyldimethoxysilane,Vinylmethyldiethoxysilane, Allyltriethoxysilane, Vinyltriacetoxysilane,Vinyltrichlorosilane, Vinyldimethylchlorosilane,Vinylmethyldichlorosilane, Vinyltris(Methylisobutylketoxime)Silane,Methylvinyldi(Cyclohexanoneoxime)Silane,Methylvinyldi(Methylethylketoxime)Silane,Vinyltris(Methylethylketoxime)Silane,3-Methacryloxypropyltrimethoxysilane,Methacryloxypropyltris(Trimethylsiloxy)Silane,3-Methacryloxypropyltriethoxysilane,3-Methacryloxypropylmethyldimethoxysilane,3-Methacryloxypropylmethyldiethoxysilane,Methacryloxymethyltriethoxysilane, 3-Mercaptopropyltrimethoxysilane,3-Mercaptopropyltriethoxysilane, 3-Mercaptopropylmethyldimethoxysilane,Bis(Triethoxysilylpropyl)Tetrasulfide,Bis(Triethoxysilylpropyl)Disulfide,Bis(Triethoxysilylpropyl)Polysulfide, Thiocyanto silane:3-Thiocyanatopropyltriethoxysilane, 3-Glycidoxypropyltrimethoxysilane,3-Glycidoxypropyltriethoxysilane, 3-Glycidoxypropylmethyldiethoxysilane,3-Glycidoxypropylmethyldimethoxysilane, Vinyltriacetoxysilane.

The definitions of “relatively hydrophilic silane component” and“relatively hydrophobic silane component” mean that inclusion in asingle layer, or within distinct layers of an abrasive particle, of twosilane components that differ in affinity for water, will constitute thepresence of a “relatively hydrophilic silane component” and a“relatively hydrophobic silane component.” Further, preferably, at leastone of the silanes can chemically react with a component of a binderresin employed to form a coated abrasive product or bonded abrasive toolof the invention. In a more preferred embodiment, at least one of thesilanes forms a covalent bond with a component of the binder resin.Suitable resins are such as are known in the art.

Typically, the weight ratio of film that includes relatively hydrophilicand relatively hydrophobic silane components over an abrasive grain isin the range of between about 1:99 and about 99:1 of relativelyhydrophilic silane component to relatively hydrophobic silane component.In a preferred embodiment, the ratio is in a range of between about 1:49and about 49:1. In a particularly preferred embodiment, the ratio is ina range of between about 1:9 and about 9:1.

The weight ratio of film to abrasive particle in a coated abrasiveparticle of the invention typically is in a range between about 1:8000and about 1:400. In a preferred embodiment the weight ratio is betweenabout 1:6000 and about 1:300. In an even more preferred embodiment, theweight ratio is in a range of between about 1:4000 and about 1:200.

The thickness of a coating that includes relatively hydrophilic anrelatively hydrophobic silane components over an abrasive particle canbe, for example, in a range of between about 1 angstrum (Å) and 5microns. In a preferred embodiment the thickness of the coating isbetween about 10 Å and about 2 microns. In another embodiment, thethickness of the coating is a range of between about 15 Å and about 1micron.

Generally, any abrasive particle that is suitable as an abrasive inindustrial or commercial applications is suitable for use in theinvention. A suitable material for abrasive particles useful in theinvention can be of any conventional abrasive particle material utilizedin the formation of coated abrasive tools. Examples of suitable abrasiveparticle materials for use in the invention include diamond, corundum,emery, garnet, chert, quartz, sandstone, chalcedony, flint, quartzite,silica, feldspar, pumice and talc, boron carbide, cubic boron nitride,fused alumina, ceramic aluminum oxide, heat treated aluminum oxide,alumina zirconia, glass, silicon carbide, iron oxides, tantalum carbide,cerium oxide, tin oxide, titanium carbide, synthetic diamond, manganesedioxide, zirconium oxide, and silicon nitride.

Other suitable grains include agglomerates such as are described in U.S.Pat. No. 6,797,023, the teachings of which are incorporated herein byreference in their entirety. A coated abrasive product of the inventioncan include particulate material containing green, unfired abrasivecomprising abrasive grit particles and nanoparticle binder, as describedin U.S. application Ser. No. 12/018,589, filed Jan. 23, 2008, theteachings of which are incorporated herewith in their entirety.

The abrasive materials can be oriented or can be applied to thesubstrate without orientation (i.e., randomly), depending upon theparticular desired properties of the coated abrasive tools. In choosingan appropriate abrasive material, characteristics, such as size,hardness, compatibility with workpieces and heat conductivity, aregenerally considered. Abrasive particle materials useful in theinvention typically have a particle size ranging from about 10nanometers (nm) to about 6 millimeters (mm), such as from about 100 nmto about 3 mm, or from about 1 micron (μ) to about 600μ.

The film of surface-modified abrasive particles of the invention caninclude a single or a plurality of layers. In one embodiment, the filmis a single layer that includes a relatively hydrophilic silanecomponent and a relatively hydrophobic silane component. Each of therelatively hydrophilic and relatively hydrophobic silane components canindependently be included in the coating as an independent monomer unit,an oligomer or a polymer. Further, the relatively hydrophilic andrelatively hydrophobic silane components can be components of oligomersor polymers. The polymers can be co-polymers or block co-polymers, suchas random block co-polymers, of at least one of the hydrophilic andrelatively hydrophobic silane components. Similarly, oligomers caninclude at least one of the relatively hydrophilic and relativelyhydrophobic silane components.

In another embodiment, the film of the surface-modified abrasive grainof the invention includes a first film layer proximate to the abrasiveparticle that includes only, or predominately, a relatively hydrophilicsilane component, as opposed to relatively hydrophobic silane component.A second, or distal film layer of the film predominately includes arelatively hydrophobic silane component as opposed to the relativelyhydrophilic silane component. It is believed that surface-modificationof an abrasive particle with a relatively hydrophilic silane componentsignificantly increases wettability of the particle and provides abetter seal against water when an abrasive product that employs thesurface-modified abrasive grain is in use. It is further believed that,typically, the relatively hydrophilic silane component will form arelatively high proportion of covalent bonds with the abrasive grainsubstrate. It is also believed that the relatively hydrophobic silanecomponent will bind tightly both with the relatively hydrophilic silanecomponent and with materials generally employed as make coats of coatedabrasive products and with bond materials of bonded abrasive products.

In one embodiment, a method of forming a surface-modified abrasive grainof the invention includes combining relatively hydrophobic andrelatively hydrophilic silane components to form a mixture. The mixtureis combined with a solvent to form a silane solution. Examples ofsuitable solvents include isopropyl alcohol, ethanol, methanol, toluene,acetone, water and mixtures thereof. The amount of solvent employed isat least sufficient to dissolve the silane components. In oneembodiment, the pH of the solution can be adjusted to a suitable pH,such as a pH in a range of between about 3 and about 7, or, morepreferably, between about 4 and about 6. An example of a suitable methodby which the pH can be adjusted is addition of acetic acid. Othermethods of adjusting the pH include, for example, use of maelic acid,stearic acid, maelic anhydride, weak solutions of HCl, HNO₃, H₂SO₄,ammonium chloride, ammonium hydroxide, sodium hydroxide solution,potassium hydroxide solution. The solution is reacted to form an atleast partially oligomerized silane solution. Further, depending uponthe silane component employed, the solution can be at least partiallyhydrolyzed to form a hydrolyzed solution. The at least partiallyoligomerized silane solution, is then blended with an abrasive graincomponent to form the surface-modified abrasive grain. In oneembodiment, the surface-modified abrasive grain is exposed to ambient,or, alternatively, some elevated temperature, or other suitableconditions, to thereby cure the film. Preferably, the surface-modifiedgrain is cured at a temperature in a range of between about 10° C. andabout 300° C. Also, preferably, the period of time of the curing is in arange of between about 15 minutes and about 24 hours. In one embodimentthe surface-modified grain is cured at a temperate of about 10° C. forabout 24 hours. In another embodiment, the surface-modified grain iscured at a temperature of about 80° C. for about 3 hours, and in stillanother embodiment, the surface-modified grain is cured at a temperatureof about 100° C. for about 1.5 hours. In another embodiment, thesurface-modified grain is cured at a temperature of about 200° C. forabout 30 minutes, or at about 300° C. for about 15 minutes.

In a preferred embodiment, the relatively hydrophilic silane componentis 3-aminopropyltriethoxy silane, the relatively hydrophobic silanecomponent is γ-methacryloxypropyltrimethoxy silane and a weight ratio ofthe two is about 1:1. In this preferred embodiment, the abrasive grainis a seeded-gel ceramic grain or powder, having a mean particle diameterof about 100 microns. The weight ratio of silane component to weight ofabrasive particles is about 1:1000. The solvent is isopropyl alcohol andthe pH is adjusted to a range of about 3-7 with glacial acetic acid. Thesurface-modified abrasive particles of this embodiment are cured at atemperature of a about 80° C. for a period of time of about 3 hours.

In another embodiment, the invention is a coated abrasive product. Anexample of a coated abrasive product of the invention is shown inFIG. 1. As shown therein, coated abrasive product 10 includes backinglayer 12. Examples of suitable backing layers include polyester, cotton,polycotton, rayon, and paper/with or without saturation/with or withoutbackfill/frontfill/non-woven products/backingless abrasives as is knownin the art. Make coat 14 on backing layer 12 is formed of a suitablematerial, such as acrylic, phenolic, etc., as is known in the art.Surface-modified abrasive grains 16 of the invention are embedded inmake coat 14. Coated abrasive product 10 can, optionally, include asuitable size coat 18 and supersize coat 20, as is known in the art.

Coated and bonded abrasive products of the invention can optionallyfurther include one or more additives, such as fillers, coupling agents,fibers, lubricants, surfactants, pigments, dyes, wetting agents,grinding aids, anti-loading agents, anti-static agents and suspendingagents. In one embodiment, a filler component that can be employed inthe invention includes a cryolite and at least one member selected fromthe group consisting of a hexafluorophosphate, a hexafluoroferrate, ahexafluorozirconate and ammonium tetrafluoroborate ((NH₄)BF₄). Examplesof hexafluorophosphates (salts of PF₆ ⁻) include ammonium salt((NH₄)PF₆), alkali metal salts (e.g., LiPF₆, NaPF₆, KPF₆, CsPF₆, etc.)and alkaline earth metal salts (e.g., Mg(PF₆)₂, Ca(PF₆)₂, Sr(PF₆)₂,Ba(PF₆)₂, etc.), and mixed salts thereof (e.g., ammonium and sodiumsalts, such as (NH₄)Na(PF₆)₂, ammonium and potassium salts, such as(NH₄)K(PF₆)₂, sodium and potassium salts, such as NaK(PF₆)₂, etc.).Specific examples of hexafluorophosphates include sodiumhexafluorophosphate (NaPF₆) and potassium hexafluorophosphate (KPF₆),and combinations thereof. Examples of hexafluoroferrates (salts of FeF₆³⁻) include ammonium salt ((NH₄)₃FeF₆), alkali metal salts (e.g.,Li₃FeF₆, Na₃FeF₆, K₃FeF₆, Cs₃FeF₆, etc.) and alkaline earth metal salts(e.g., Mg₃(FeF₆)₂, Ca₃(FeF₆)₂, Sr₃(FeF₆)₂, Ba₃(FeF₆)₂, etc.), and mixedsalts thereof (e.g., ammonium and sodium salts, such as (NH₄)Na₂FeF₆ and(NH₄)₂NaFeF₆, ammonium and potassium salts, such as (NH₄)K₂FeF₆ and(NH₄)₂KFeF₆, sodium and potassium salts, such as K₂NaFeF₆ and KNa₂FeF₆,calcium and sodium salts, such as CaNaFeF₆, calcium and potassium salts,such as CaKFeF₆, etc.). Specific examples of hexafluoroferrates includeammonium hexafluoroferrate ((NH₄)₃FeF₆) and alkali metalhexafluoroferrates, such as sodium hexafluoroferrate (Na₃FeF₆) andpotassium hexafluoroferrate (K₃FeF₆), and combinations thereof. Examplesof hexafluorozirconates (salts of ZrF₆ ²⁻) include ammonium salt((NH₄)₂ZrF₆), alkali metal salts (e.g., Li₂ZrF₆, Na₂ZrF₆, K₂ZrF₆,Cs₂ZrF₆, etc.) and alkaline earth metal salts (e.g., MgZrF₆, CaZrF₆,SrZrF₆, BaZrF₆, etc.), and mixed salts thereof (e.g., ammonium andsodium salts, such as (NH₄)NaZrF₆, ammonium and potassium salts, such as(NH₄)KZrF₆, sodium and potassium salts, such as NaKZrF₆, etc.). Specificexamples of hexafluorozirconates include ammonium hexafluorozirconate((NH₄)₂ZrF₆) and alkali metal hexafluorozirconates, such as sodiumhexafluorozirconate (Na₂ZrF₆) and potassium hexafluorozirconate(K₂ZrF₆), and combinations thereof. In a specific embodiment, at leastone of the hexafluorophosphate, the hexafluoroferrate and thehexafluorozirconate is an ammonium salt or a sodium salt. In yet anotherspecific embodiment, the hexafluorophosphate is ammoniumhexafluorophosphate, the hexafluoroferrate is sodium hexafluoroferrate,and the hexafluorozirconate is sodium hexafluorozirconate. In yetanother specific embodiment, the filler component includes at least onemember selected from the group consisting of ammoniumhexafluorophosphate, sodium hexafluoroferrate, sodiumhexafluorozirconate and ammonium tetrafluoroborate. In yet anotherspecific embodiment, the filler component includes at least one memberselected from the group consisting of ammonium hexafluorophosphate,sodium hexafluoroferrate and sodium hexafluorozirconate. In yet anotherspecific embodiment, the filler component includes at least one memberselected from the group consisting of sodium hexafluorozirconate andsodium hexafluoroferrate.

As used herein, a “cryolite” means a salt of aluminum hexafluoride (AlF₆³⁻), such as an alkali metal salt, an alkaline earth metal salt, or anammonium salt, or a combination thereof. Examples of cryolites includelithium aluminum hexafluoride (Li₃AlF₆), sodium aluminum hexafluoride(Na₃AlF₆), potassium aluminum hexafluoride (K₃AlF₆), ammonium aluminumhexafluoride ((NH₄)₃AlF₆), sodium ammonium hexafluoride (e.g.,K(NH₄)₂AlF₆ or K₂(NH₄)AlF₆), potassium ammonium aluminum hexafluoride(e.g., Na(NH₄)₂AlF₆ or Na₂(NH₄)AlF₆), sodium potassium ammoniumhexafluoride (i.e., NaK(NH₄)AlF₆), lithium ammonium aluminumhexafluoride (e.g. Li(NH₄)₂AlF₆ or Li₂(NH₄)AlF₆), etc. In one specificembodiment, sodium aluminum hexafluoride (Na₃AlF₆) is employed as acryolite. The cryolite generally is present in an amount in a range ofbetween about 2 wt % and about 98 wt %, such as between about 2 wt % andabout 65 wt %, between about 2 wt % and about 50 wt %, of the fillercomponent. In a specific embodiment, the amount of the cryolite is in arange between about 2 wt % and about 30 wt %, or between about 2 wt %and about 20 wt % of the filler component.

In another embodiment, the filler component that can be employed in theinvention includes at least one member selected from the groupconsisting of a hexafluoroferrate, a hexafluorophosphate and ahexafluorozirconate. Suitable examples, including particular examples,of the hexafluoroferrate, the hexafluorophosphate and thehexafluorozirconate are as described above. In one specific embodiment,at least one of the hexafluoroferrate and the hexafluorozirconate is anammonium salt or a sodium salt. In another specific embodiment, thefiller component includes at least one member selected from the groupconsisting of a hexafluoroferrate and a hexafluorozirconate. In anotherspecific embodiment, the filler component includes at least one memberselected from the group consisting of sodium hexafluoroferrate andsodium hexafluorozirconate. Any suitable amount of thehexafluoroferrate, the hexafluorophosphate and the hexafluorozirconatecan be employed in the invention.

In a specific embodiment, the hexafluoroferrate, the hexafluorophosphateand the hexafluorozirconate, disclosed herein, is each independentlypresent in a range of between about 2 wt % and about 100 wt % of thefiller component, such as between about 2 wt % and about 98 wt %,between about 35 wt % and about 98 wt % or between about 50 wt % andabout 98 wt %, of the filler component. Alternatively, in an embodimentfurther employing a cryolite, the hexafluoroferrate, thehexafluorophosphate and the hexafluorozirconate is each independentlypresent in a range of between about 2 wt % and about 98 wt % of thefiller component, such as between about 35 wt % and about 98 wt % orbetween about 50 wt % and about 98 wt %, of the filler component.

In another specific embodiment, the filler component of the invention ispresent in an amount in a range between about 0.5 wt % and about 50 wt%, between about 10 wt % and about 50 wt %, between about 0.5 wt % andabout 20 wt %, or between about 10 wt % and about 20 wt %, of the weightof the abrasive component.

In some embodiments, the filler component is incorporated into a bondcomponent for abrasive products, such as coated abrasive products andbonded abrasive products. The bond component also includes a binder. Anysuitable bond material known in the art can be used for the binder. Thebinder can be an inorganic binder or an organic binder. Suitableexamples of organic binders include hide glue, urethane resins, acrylateresins, polyvinyl alcohols, epoxy resins, phenolic resins,urea-formaldehyde phenolic resins, aminoplast resins andmelamine-formaldehyde resins, and combinations thereof. Suitableexamples of inorganic binders include cement, calcium oxide, clay,silica, magnesium oxide, and combinations thereof. Specific examples ofsuitable inorganic binders can be found in U.S. Pat. Nos. 4,543,107;4,898,597; 5,203,886; 5,025,723; 5,401,284; 5,095,665; 5,536,283;5,711,774; 5,863,308; and 5,094,672, the entire teachings of all ofwhich are incorporated herein by reference. Specific binder(s) includedin the bond component can be chosen depending upon particularapplication(s) of the bond component, for example, types of abrasiveproducts and/or coats employing the bond component.

A suitable method of fabricating a coated abrasive product of theinvention includes combining surface-modified abrasive grains of theinvention with a resin that will become the make coat. The combinedsurface-modified abrasive grains and resin are applied to the backing,and the resin is then cured by a suitable method, such as by radiation,thermal, microwave, RF polymerization, individually or in anycombination, as is known in the art.

In another embodiment, the invention is bonded abrasive product, such asbonded wheel 22, shown in FIG. 2. Wheel 22 includes a bond component andan abrasive grain component of the invention that includes an abrasivegrain, and a film over the abrasive grain, wherein the coating includesa relatively hydrophobic silane component and a relatively hydrophilicsilane component. A method of fabricating a bonded abrasive product ofthe invention includes a resin or a vitreous glass bond along with abinder. The green compound is molded or formed into the desired shapeand subsequently thermally cured or fired to result in the finalproduct.

In still another embodiment, the invention includes a method of grindingor cutting the work piece. The method includes the step of applying tothe work piece an abrasive product of the invention that includes apolymerized combination of relatively hydrophilic and hydrophobic silanecomponents. The abrasive product employed in the method can, forexample, be either a coated abrasive product or a bonded abrasiveproduct.

The following examples are representative only, and not intended to belimiting.

EXEMPLIFICATION Example 1

The following components were used for the preparation of the silanetreated grain:

-   -   Grain used was seeded sol-gel alumina grain    -   A-174 silane→γ-methacryloxypropyltrimethoxy silane    -   A-1100 silane→3-aminopropyltriethoxy silane    -   DI water    -   Isopropyl alcohol

Procedure for Silane Treatment of Grain:

The silane treatment of the abrasive grain included three steps, namely(1) the preparation of the silane solution, (2) mixing of the preparedsilane solution with the abrasive grain and blending the mix, and (3)curing the subsequent silane treated grain at elevated temperature.

Step 1. The recipe for preparing the silane solution was as follows:

The silane solution was prepared by starting out with measuring 5.68grams of the γ-methacryloxypropyltrimethoxy silane and 5.68 grams of the3-aminopropyltriethoxy silane. The two silanes were mixed using amagnetic stirrer. To this mixture 101.25 grams of isopropyl alcohol wasadded with continued agitation of the mix. Once the silane mixtures wasdispersed in the isopropyl alcohol, 11.35 gram of DI water was added tothe mix. Glacial acetic acid was added to the mix to attain a pH of 5-6and the solution was left under agitation for 3-4 hours for hydrolysisof the silane.

Step 2. Treatment of the abrasive grain with the silane solutionprepared in step 1:

For treating the abrasive grain with the silane solution prepared inStep 1, a V-blender with an intensifier bar was used. The V-blender wasloaded with 9090.91 grams of seeded gel SG P150 grain to correspond withthe amount of silane solution prepared in Step 1. The silane was pumpedinto the V-blender at around 5-7 milliliters per minute while theV-blender was on and turning. Once all the silane solution prepared inStep 1 had been pumped into the V-blender, the mixture was allowed toblend in the V-blender for another 15-20 minutes. The contents of theV-blender were then taken out of the V-blender and processed throughStep 3.

Step 3. Curing the silane treated grain The V-blended seeded gel grainwas subsequently cured in an oven at 80° C. for 3 hours to produce thefinal silane treated grain used for preparing the make resin slurry andin the electrostatic grain projection.

Example of Using Silane Treated Grain:

Formulation #1 Recipe:

Component Supplier Wt. Percentage, % Bisphenol-A epoxy diacrylate Cytec38.73% with 40% TMPTA (Trimethylol- propane triacrylate) Acidic acrylateoligomer Sartomer, Cytec 2.17% (CN-147 from Cytec) Defoamer BYK A501(poly- BYK 0.1% siloxane-based) 2-Hydroxy-2-methyl-1-phenyl- Cytec,Lamberti, 1% propanone Ciba Bis (2,4,6- Ciba 1% trimethylbenzoyl)phenyl-phosphine oxide Calcium silicate NYCO 35% Seeded-Gel Grain P150 gritSaint-Gobain 22% (treated or untreated)The mixing instructions were as follows:

-   -   1. Add bisphenol-A epoxy diacrylate with 40% TMPTA mixture to        mix vessel.    -   2. Add acidic acrylate oligomer under agitation.    -   3. Add defoamer BYK A501 under agitation.    -   4. Add 2-hydroxy-2-methyl-1-phenyl-propanone under agitation.    -   5. Add bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide. Mix is        fully dissolved.    -   6. Add wollastonite. Mix 5 minutes.    -   7. Add grain. Mix for 30 minutes.

Belt Preparation:

Engineered abrasive belts were prepared by employing the followingsteps:

-   -   Coating the slurry mix prepared as above on Y-weight polyester        backing    -   Electro-statically coated with grains    -   Embossing the pattern    -   UV-curing and rewind    -   Postcure at 275° F. for 18 hour    -   Flex the web and make a 6″×98″ belt for testing        The Test protocol was as follows:

Test machine: Loeser RSP374 centerless

Contact Wheel: 65 Shore A 1:3 serrated

Regulating wheel: 55 Shore A

Belt speed: 7400 SFPM

Contact Wheel speed: 1766 RPM

Regulating Wheel speed: 112 RPM

Belt Tension: 40 lbs

Regulating wheel tilt degree: 5

Reg. Wheel Swing Deg.: 2

Contact wheel pressure: 85 PSI

Regulating wheel pressure: 65 PSI

Applied forces: 30 or 50 lbs

Coolant: 2% Trimclear in DI water

Work piece material: 1045 CS; hardness 13.49 Rc

Work piece dimension: Φ1.5″×20″ long

The Test Procedure was as Follows:

Work pieces were passed through the centerless machine at setting force.The weight and surface finish of the parts and the thickness of the beltat three designated location were taken at part 1, 2, 5, 10, 15, 20, andthen every 20 parts.

Results and Conclusions

Two batches of belts were prepared using the formulation shown above.The control used grains without any treatment. Another batch usedaforementioned surface-modified grains. The belts were tested on aLoesser centerless grinder with 30 lbs (FIGS. 3A-3D) or 50 lbs (FIGS.4A-4D) applied force. In general, silane treatment improved grindingperformance and the life of the belts at both low and high force loads.As shown in FIGS. 5A and 5B, belts made with silane treated grainsshowed 49% higher average MRR from part 10 to 100 and 39% less abrasiveloss after grinding 100 parts than non-treated versions at 30 lbs load,and at a higher load of 50 lbs, a similar trend followed. As can be seenin FIG. 6. The impact on belt life can also be observed from beltappearance after 100 parts as shown in the photograph: severe abrasivecoating loss was presented on the control belt (bottom) compared tobelts with surface-modified grain (top).

Example 2 Methodology of Sample Preparation for Samples of AnotherEmbodiment of the Invention 1. Surface Treatment for Abrasive Grain

1.1. Materials used:

-   -   FRPL grain P800 grit size→obtained from Treibacher    -   BFRPL grain P800 grit size→obtained from Treibacher    -   A-174 silane→γ-methacryloxypropyltrimethoxy silane    -   A-1100 silane→3-aminopropyltriethoxy silane    -   A-1289 silane→Bis-[triethoxysilylpropyl] tetrasulfide    -   Isopropyl alcohol    -   Deionized water        All silanes procured from OSi Specialites Inc. Currently they        can be procured from Momentive Performance Materials

1.2. Steps of Silane Treatment of Abrasive Grain:

-   -   1.2.1. Step 1: the first step of the surface treatment of the        grain involves preparation of the silane solution to be used for        the treatment. Three silane treatments were used to treat both        the BFRPL and FRPL P800 grit used in this experiment. The silane        treatments differed in the type of silane chosen for the        treatment and were namely, (1) A-174 silane alone, (2)        combination of A-174 and A-1100 silane, and (3) A-1289        bis-sulfur silane. The amount of silane: water: isopropyl        alcohol for each of the above 3 treatments to process a batch of        8 kg abrasive grain is shown in Table 1.

TABLE 1 Description of ratios for the 3 types of silane treatment usedto treat 8 kgs of BFRPL and FRPL P800 alumina abrasive grain AmountAmount Amount Isopropyl DI Treatment of A-174 of A-1100 of A-1289alcohol water Type silane (g) silane (g) Silane (g) (g) (g) A-174 5.0 —— 90 5 silane alone A-174 And 4.5 0.5 — 90 5 A-1100 silane combinationA-1289 — — 5 90 5 silane alone

To prepare the silane solution for the pretreatment the requisite amountof silane was added to the beaker. If two silanes were to be used, as inthe combination of A-174 and A-1100 silane both the silanes were addedin the requisite amount and mixed in a beaker using a shear mixer. Tothis mixture the specified amount of isopropyl alcohol was added whilecontinuing the agitation. At this point the pH was adjusted to 5 usingglacial acetic acid. Further, the specified amount of water was addedwith continued stirring and the solution was left to stand for 3.5 hoursfor hydrolysis.

-   -   1.2.2. Step 2: The untreated abrasive grain (8 kg) was put in        the V-blender with an intensifier bar and the silane solution        prepared in step 2 above was pumped into the V-blender while        rotating and mixing over a period of 15 minutes. The V-blender        was left to continue to rotate over a period of another 1 hour        to ensure complete mixing of the silane solution with the        abrasive grain. Thereafter the V-blender was stopped and emptied        out resulting in the silane treated grain.    -   1.2.3. Step 3: The step 4 of treatment of the grain comprised of        leaving the silane treated grain obtained from step 3 in a fume        hood overnight for the isopropyl alcohol to be driven out and        then heating the grain at 200° F. for 3 hours.    -   1.2.4. Step 4: The last step of the surface treatment of the        grain is flow treatment of the grain using 0.05 wt % of Cabosil        untreated amorphous silica of commercial grade Cabosil M5        obtained from Cabot Corporation. This is achieved by mixing the        amount of grain and Cabosil in a V-blender with an intensifier        bar and blending the mixture for approximately an hour to ensure        uniform distribution of the flow treatment. The flow treatment        was done to all the samples including the non-silane treated        grain and the silane-treated grain (described below) to ensure        ease in projection during the subsequent electrostatic        projection, a step in processing to make an abrasive disc.    -   1.2.5. The above treatment procedure resulted in 6 types of        abrasive grains, namely (1) A-174 silane treated BFRPL        grain, (2) A-174 silane treated FRPL grain, (3) A-174 and A-1100        combination silane treated BFRPL grain, (4) A-174 and A-1100        combination silane treated FRPL grain, (5) bis-sulfur silane        treated BFRPL grain and (6) bis-sulfur silane treated FRPL        grain. Also, prepared were 2 more control abrasive grains        namely (1) non-silane treated BFRPL grain and (2) non-silane        treated FRPL grain. All the above 8 abrasive grains were flow        treated according to Step 4

2. Steps for Making the Make Resin Mix

-   -   2.1. Step 1: Bis-phenol-A-diacrylate was preheated at        125-135° F. for 24 hours. 1,6 Hexinedioal diacrylate,        Trimethylolpropane triacrylate, BYK-501 defoamer, FC-171 and        KR-55 were weighed out in their respective quantities in a drum        and the preheated Bis-phenol-A-diacrylate was added to the mixed        to this for 30-45 minutes using Meyers high speed disperser with        8: dia blade. The amount of each quantity used for the above        components is specified in Table 2. The mixing was stopped and        the walls and base of the drum was checked for undissolved        resin. If there was inhomogenity in the mix the solution was        continued to be mixed till a homogeneous solution was obtained.        The viscosity range for the mix for a 80° F. solution was        maintained between 400-500 cps. This mix was then stored in dark        in ambient temperatures conditions preferably under 90° F.±2° F.

TABLE 2 Description of amounts in percents for the components of thebase resin mix for the make resin Product Name Description ManufactererAmount (%) Bis-phenol-A-diacrylate Ebecryl 3700, 49.63 Cytec, Sartomer1,6 Hexinedioal Cytec, Sartomer 24.88 Trimethylolpropane Cytec, Sartomer24.88 triacrylate Defoamer BYK-501, BYK 0.24 Tetra (2,2 KR-55, Kenrich0.17 diallyloxymethyl)butyl, Petrochemicals di(ditridecyl)phosphitotitanate, Fluorochemical Fluorad Bran 0.20 Surfactant FC171, 3M

-   -   2.2. Step 2: The second step was to prepare the catalyst        solution for the make resin mix. For this, the V-pyrol was        weighed in the desired quantity specified in Table 3. To this        mix Irgacure 651 was mixed under moderate agitation until        dissolved (approximately 20 minutes). This mix was then stored        in a cool dark place under 90° F.±2° F.

TABLE 3 Description of amounts in percents for the components of thecatalyst mix for the make resin Product Name Description ManufactererAmount (%) N-Vinyl-2- BASF, Polysciences, 77.78 pyrrolidone ISP2,2-Dimethoxy-1,2- Irgacure 651, Ciba 22.22 diphenylethan-1-oneSpeciality Chemicals

-   -   2.3. Step 3: The catalyst from Step 2 was measured out and to        this the resin premix from Step 1 was added with the mix ratio        being 7:33 by weight for the mix from Step 2: Step 1. This was        mixed at high speed with disperser using a 4″ shear blade or        equal. Mixing was done at 1780 SFPM for approximately 15 minutes        or until a homogeneous solution was obtained. The viscosity        range of the resulting solution was noted between 150-200 cps        using a Brookfield viscometer.        3. Steps for making the size resin mix    -   3.1. Step 1: For the first step of preparing the size resin mix        isopropyl alcohol was mixed with water using a small air mixer        in a clean container. To this silane A-1100 was slowly added        while mixing with continued agitation thereafter for another 20        minutes to prepare the silane A-1100 mix used in the next step.        The ratios of the mix were as per Table 4.

TABLE 4 Percentage of components used for preparing silane A-1100 mixProduct name, Description Manufacturer Amount (%) 3- Silane A-1100, OSi50.63 aminorpopyltriethoxy Specialities Inc. silane Isopropyl alcohol —37.11 Water — 12.26

-   -   3.2. Step 2: Tris (2-hydroxyethyl) isocyanurate acrylate,        2-Hydroxy-2-Methylpropiophenone, Fluorochemical Surfactant FC        171 and defoamer BYK-501 were mixed together in a drum, as        specified in Table 5., for around 20-30 minutes at slow speed of        10000 SFPM. To this the silane A-1100 mix prepared in Step 1        above was slowly added and mixed for 10 minutes at a slow speed.        It is essential that the silane A-1100 mix be added to the base        resin mix under agitation to avoid formation of gelatin. This        mix has a good shelf life of 2 weeks in a plastic container.

TABLE 5 Description of amounts in percents for the components of thebase resin mix for the size resin Product name, Description ManufacturerAmount (%) Tris (2-hydroxyethyl) SR-368, 94.06 isocyanurate acrylateSartomer 2-Hydroxy-2- Daracure 1173, 3.77 Methylpropiophenone CibaSpeciality Chemicals, Lamberti, Ciba Fluorochemical Fluorad Bran 0.09Surfactant FC171, 3M Defoamer BYK-501, BYK 0.23 Silane A-1100 mix — 1.85

4. Preparation of the Abrasive Article

-   -   4.1. The preparation of the abrasive article from which abrasive        discs were subsequently stamped out for performance evaluation        testing started with the unwind station where a 3 mil PET roll        was unwound. Onto this web the make resin prepared above was        applied to obtain a make resin weight of around 0.52 lbs/ream.        This was B-staged (partially cured) using UV lights (D and H        bulbs). The partially cured make on the 3 mil PET backing was        passed through an electrostatic grain projection unit to apply        the abrasive grain silane and flow treated as described above. 8        different runs were carried out for each of the different 8        surface treated grains prepared above. Following the        electrostatic projection of the abrasive grain to result in        grain weights of around 1.7 lbs/ream a full cure of the maker        resin was done using UV lights (D & H bulbs). To the cured make        resin and abrasive grain surface another layer of the size resin        was applied and cured fully using UV lights (D and H bulb)        sequence. The cured product was wound up into a jumbo roll on        the rewind station. These jumbos were subsequently converted        into 6″ abrasive discs and used for testing as described below.        5. Testing of the abrasive article    -   5.1. A DA sander was used to test the performance of the above 8        types of discs.

For the testing 6, 30 seconds grind cycles were used under dry grindingconditions. The substrate being ground was chosen as an acrylic panelusing 6 panels such that each cycle would start afresh on a newlyprepared sample. After each 30 seconds grind cycle the ground panel wasweighed to measure the loss in weight and the material removal wasrecorded.

Results and Conclusions

Coated abrasive disks were made as described with variation in grain andgrain treatment. Treated FRPL and BFRPL Grains, which included singlesilane A174, bis-sulfur silane, and combination of A 174 and A 1100,were all evaluated against the control made by raw FRPL and BFRPL. Forboth grain types, disks with combination silane (combination ofrelatively hydrophilic silane component and relatively hydrophobicsilane component) treatment grains showed the highest cumulativematerial removed compared to control and single (single silanecomponent) treated grain versions. Although CMR of one of thesingle-silane-treatment versions performed close to that of thecombination treatment (of relatively hydrophilic and relativelyhydrophobic silane components) of the invention, the material removalrate after an initial break-in period of 30 seconds showed greatadvantage of combination-treated grain of the invention relative tograin treated with only a single silane component.

EQUIVALENTS

While this invention has been particularly shown and described withreference to exampled embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

1. A surface-modified abrasive grain, comprising: a) an abrasive grain;and b) a film on the abrasive grain, the film including a relativelyhydrophilic silane component and a relatively hydrophobic silanecomponent.
 2. The surface-modified abrasive grain of claim 1, whereinthe relatively hydrophilic silane component includes at least onecompound from at least one member selected from the group consisting ofamines, diamines, triamines, azine, azol, ureido, isocyanate, alkoxy,acetoxy, oximino, chloro, morpholinyl and piperazinyl silanes.
 3. Thesurface-modified abrasive grain of claim 1, wherein the relativelyhydrophobic silane includes at least one compound from at least onemember selected from the group consisting of vinyl silanes, methacrylatesilanes, sulfur silanes, mercapto silanes, epoxy silanes and phenylsilanes.
 4. The surface-modified abrasive grain of claim 1, wherein thegrain is at least one member selected from the group consisting ofaluminum oxide, silicon carbide, fused ceramics, alloy abrasives,sol-gels, ceramic grains and super abrasives. diamond, corundum, emery,garnet, chert, quartz, sandstone, chalcedony, flint, quartzite, silica,feldspar, pumice, talc, boron carbide, cubic boron nitride, fusedalumina, ceramic aluminum oxide, heat treated aluminum oxide, aluminazirconia, glass, silicon carbide, iron oxides, tantalum carbide, ceriumoxide, tin oxide, titanium carbide, synthetic diamond, manganesedioxide, zirconium oxide, and silicon nitride.
 5. The surface-modifiedabrasive grain of claim 4, wherein the mean particle diameter is in arange of between about 10 nm and 6 mm.
 6. The surface-modified abrasivegrain of claim 1, wherein the silane components are polymerized asdistinct hydrophilic and hydrophobic polymers, co-polymerized, or blockco-polymerized.
 7. The surface-modified abrasive grain of claim 1,wherein the weight ratio of the relatively hydrophilic silane componentto the relatively hydrophobic silane component is in a range of betweenabout 1:99 and about 99:1.
 8. The surface-modified abrasive grain ofclaim 1, wherein the abrasive grain is seeded sol-gel alumina grain, andthe film is a polysiloxane that includes γ-methacryloxypropyltrimethoxysilane as the relatively hydrophobic silane component and3-aminopropyltriethoxy silane as the relatively hydrophilic silanecomponent.
 9. A method of forming a surface-modified abrasive grain,comprising the steps of: a) combining relatively hydrophilic andrelatively hydrophobic silane components to form a mixture; b) combiningthe mixture with a solvent to form a silane solution; c) reacting atleast a portion of the silane components to form a partiallyoligomerized silane solution; and d) blending the partially oligomerizedsilane solution with an abrasive grain component to form thesurface-modified abrasive grain.
 10. The method of claim 9, furtherincluding the step of curing the surface-modified abrasive grain. 11.The method of claim 10, wherein the relatively hydrophilic silanecomponent is at least one member selected from the group consisting ofamines, diamines, triamines, azine, azol, ureido, isocyanate, alkoxy,acetoxy, oximino, chloro, morpholinyl and piperazinyl silanes.
 12. Themethod of claim 11, wherein the relatively hydrophobic silane componentis at least one member selected from the group consisting of vinylsilanes, methacrylate silanes, sulfur silanes, mercapto silanes, epoxysilanes and phenyl silanes.
 13. The method of claim 9, wherein the grainis at least one member selected from the group consisting of diamond,corundum, emery, garnet, chert, quartz, sandstone, chalcedony, flint,quartzite, silica, feldspar, pumice and talc, boron carbide, cubic boronnitride, fused alumina, ceramic aluminum oxide, heat treated aluminumoxide, alumina zirconia, glass, silicon carbide, iron oxides, tantalumcarbide, cerium oxide, tin oxide, titanium carbide, synthetic diamond,manganese dioxide, zirconium oxide, and silicon nitride.
 14. The methodof claim 13, wherein the mean particle diameter is in a range of betweenabout 10 nm and 6 mm.
 15. The method of claim 9, wherein the silanecomponents are polymerized as distinct hydrophilic and hydrophobicpolymers, co-polymers, or block co-polymers.
 16. The method of claim 9,wherein the weight ratio of the relatively hydrophilic silane componentto the relatively hydrophobic silane component is in a range of betweenabout 1:99 to about 99:1.
 17. The method claim 9, wherein the abrasivegrain is seeded sol-gel alumina grain, and the film is a polysiloxanethat includes γ-methacryloxypropyltrimethoxy silane as the hydrophobiccomponent and 3-aminopropyltriethoxysilane as the hydrophilic component.18. The method of claim 9, wherein the solvent includes at least onemember selected from the group consisting of isopropyl alcohol, water,ethanol, methanol, toluene and acetone.
 19. The method of claim 18,wherein the pH of the silane solution is adjusted to a range of betweenabout 3 and about 7 prior to at least partially hydrolyzing the silanecomponent.
 20. The method of claim 19, wherein the pH is adjusted withat least one member selected from the group consisting of acetic acid,maelic acid, stearic acid, maelic anhydride, HCl, HNO₃, H₂SO₄, ammoniumchloride, ammonium hydroxide, sodium hydroxide solution, potassiumhydroxide solution.
 21. The method of claim 9, wherein the relativelyhydrophobic component is γ-methacryloxypropyltrimethoxy silane, therelatively hydrophilic component is 3-aminopropyltriethoxy silane, andthe solvent includes deionized water and isopropyl alcohol.
 22. Themethod of claim 21, wherein weight ratio of the relatively hydrophobicsilane component to hydrophilic silane component is in a ratio ofbetween about 1:99 and about 99:1.
 23. The method of claim 22, whereinthe grain is at least one member selected from the group consisting ofdiamond, corundum, emery, garnet, chert, quartz, sandstone, chalcedony,flint, quartzite, silica, feldspar, pumice, talc, boron carbide, cubicboron nitride, fused alumina, ceramic aluminum oxide, heat treatedaluminum oxide, alumina zirconia, glass, silicon carbide, iron oxides,tantalum carbide, cerium oxide, tin oxide, titanium carbide, syntheticdiamond, manganese dioxide, zirconium oxide, and silicon nitride. 24.The method of claim 23, wherein the surface-modified abrasive grain iscured, such as at a temperature in a range of between about 10° C. andabout 300° C. for a period of time in a range of between about 15minutes and about 24 hrs.
 25. The method of claim 24, wherein thesurface-modified abrasive grain is cured at a temperature of about 80°C. for a period of time of about 3 hours.
 26. The coated abrasiveproduct, comprising: a) a backing layer; b) a make coat on the backinglayer; and c) an abrasive grain component at the make coat, where theabrasive grain component includes abrasive grains surface-modified withat least one relatively hydrophilic silane component and at least onehydrophobic silane component.
 27. The coated abrasive product of claim26, wherein the relatively hydrophilic silane component includes atleast one compound from at least one member selected from the groupconsisting of amines, diamines, triamines, azine, azol, ureido,isocyanate, alkoxy, acetoxy, oximino, chloro, morpholinyl andpiperazinyl silanes.
 28. The coated abrasive product of claim 26,wherein the relatively hydrophobic silane component includes at leastone compound from at least one member selected from the group consistingof vinyl silanes, methacrylate silanes, sulfur silanes, mercaptosilanes, epoxy silanes and phenyl silanes.
 29. The coated abrasiveproduct of any of claim 26, wherein the grain is at least one memberselected from the group consisting of diamond, corundum, emery, garnet,chert, quartz, sandstone, chalcedony, flint, quartzite, silica,feldspar, pumice, talc, boron carbide, cubic boron nitride, fusedalumina, ceramic aluminum oxide, heat treated aluminum oxide, aluminazirconia, glass, silicon carbide, iron oxides, tantalum carbide, ceriumoxide, tin oxide, titanium carbide, synthetic diamond, manganesedioxide, zirconium oxide, and silicon nitride.
 30. The coated abrasiveproduct of claim 29, wherein the mean particle diameter is in a range ofbetween about 10 nm and 6 mm.
 31. The coated abrasive product of claim26, wherein the silane components are polymerized as distincthydrophilic and hydrophobic polymers, co-polymers, or block co-polymers.32. The coated abrasive product of claim 26, wherein the weight ratio ofthe relatively hydrophilic silane component to the relativelyhydrophobic silane component is in a range of between about 1:99 toabout 99:1.
 33. The coated abrasive product of claim 26, wherein theabrasive grain is seeded sol-gel alumina grain, and the film is apolysiloxane that includes γ-methacryloxypropyltrimethoxy silane as thehydrophobic component and 3-aminopropyltriethoxy silane as thehydrophilic component.
 34. A method of making a coated abrasive product,comprising the steps of: a) combining relatively hydrophilic andrelatively hydrophobic silane components to form a mixture; b) combiningthe mixture with a solvent to form a silane solution; c) hydrolyzing atleast a portion of the silane components to form a hydrolyzed solution;and d) blending the hydrolyzed solution with abrasive grains to formsurface-modified abrasive grains; e) combining the surface-modifiedabrasive grains with a resin; f) applying the combined surface-modifiedabrasive grains and resin to a backing; and g) curing the resin, therebyforming the coated abrasive product.
 35. The method of claim 34, furtherincluding the step of curing the surface-modified abrasive grains. 36.The method of claim 35, wherein the relatively hydrophilic silanecomponent includes at least one compound from at least one memberselected from the group consisting of amines, diamines, triamines,azine, azol, ureido, isocyanate, alkoxy, acetoxy, oximino, chloro,morpholinyl and piperazinyl silanes.
 37. The method of claim 35, whereinthe relatively hydrophobic silane component includes at least onecompound from at least one member selected from the group consisting ofvinyl silanes, methacrylate silanes, sulfur silanes, mercapto silanes,epoxy silanes and phenyl silanes.
 38. The method of any of claim 34,wherein the grain is at least one member selected from the groupconsisting of diamond, corundum, emery, garnet, chert, quartz,sandstone, chalcedony, flint, quartzite, silica, feldspar, pumice andtalc, boron carbide, cubic boron nitride, fused alumina, ceramicaluminum oxide, heat treated aluminum oxide, alumina zirconia, glass,silicon carbide, iron oxides, tantalum carbide, cerium oxide, tin oxide,titanium carbide, synthetic diamond, manganese dioxide, zirconium oxide,and silicon nitride.
 39. The method of claim 34, wherein the meanparticle diameter is in a range of between about 10 nm and 6 mm.
 40. Themethod of claim 34, wherein the silane components are polymerized asdistinct hydrophilic and hydrophobic polymers, co-polymers, or blockco-polymers.
 41. The method of claim 34, wherein the weight ratio of therelatively hydrophilic silane component to the relatively hydrophobicsilane component is in a range of between about 1:99 to about 99:1. 42.The method of claim 34, wherein the abrasive grain is seeded sol-gelalumina grain, and the film is a polysiloxane that includesγ-methacryloxypropyltrimethoxy silane as the hydrophobic component and3-aminopropyltriethoxy silane as the hydrophilic component.
 43. Themethod of claim 34, wherein the solvent includes at least one memberselected from the group consisting of isopropyl alcohol, water, ethanol,methanol, toluene and acetone.
 44. The method of claim 43, wherein thepH of the silane solution is adjusted to a range of between about 3 andabout 7 prior to at least partially hydrolyzing the silane component.45. The method of claim 44, wherein the pH is adjusted with at least onemember selected from the group consisting of acetic acid, maelic acid,stearic acid, maelic anhydride, HCl, HNO₃, H₂SO₄, ammonium chloride,ammonium hydroxide, sodium hydroxide solution, potassium hydroxidesolution.
 46. The method of claim 34, wherein the relatively hydrophobicsilane component includes γ-methacryloxypropyltrimethoxy silane, therelatively hydrophilic component is 3-aminopropyltriethoxy silane, andthe solvent includes deionized water and isopropyl alcohol.
 47. Themethod of claim 46, wherein weight ratio of the relatively hydrophobicsilane component to hydrophilic silane component is in a ratio ofbetween about 1:99 and about 99:1.
 48. The method of claim 47, whereinthe grain is at least one member selected from the group consisting ofdiamond, corundum, emery, garnet, chert, quartz, sandstone, chalcedony,flint, quartzite, silica, feldspar, pumice, talc, boron carbide, cubicboron nitride, fused alumina, ceramic aluminum oxide, heat treatedaluminum oxide, alumina zirconia, glass, silicon carbide, iron oxides,tantalum carbide, cerium oxide, tin oxide, titanium carbide, syntheticdiamond, manganese dioxide, zirconium oxide, and silicon nitride. 49.The method of claim 48, wherein the surface-modified abrasive grain iscured, such as at a temperature in a range of between about 10° C. andabout 300° C. for a period of time in a range of between about 15minutes and about 24 hrs.
 50. The method of claim 49, wherein thesurface-modified abrasive grain is cured at a temperature of about 80°C. for a period of time of about 3 hours.
 51. A bonded abrasive product,comprising: a) a bond component; and b) an abrasive grain component thatincludes an abrasive grain and a film over the abrasive grain, the filmincluding a relatively hydrophilic silane component and a relativelyhydrophobic silane component.
 52. The bonded abrasive product of claim51, wherein the relatively hydrophilic silane component includes atleast one compound from at least one member selected from the groupconsisting of amines, diamines, triamines, azine, azol, ureido,isocyanate, alkoxy, acetoxy, oximino, chloro, morpholinyl andpiperazinyl silanes.
 53. The bonded abrasive product of claim 51,wherein the relatively hydrophobic silane component includes at leastone compound from at least one member selected from the group consistingof vinyl silanes, methacrylate silanes, sulfur silanes, mercaptosilanes, epoxy silanes and phenyl silanes.
 54. The bonded abrasiveproduct of any of claim 51, wherein the grain is at least one memberselected from the group consisting of diamond, corundum, emery, garnet,chert, quartz, sandstone, chalcedony, flint, quartzite, silica,feldspar, pumice, talc, boron carbide, cubic boron nitride, fusedalumina, ceramic aluminum oxide, heat treated aluminum oxide, aluminazirconia, glass, silicon carbide, iron oxides, tantalum carbide, ceriumoxide, tin oxide, titanium carbide, synthetic diamond, manganesedioxide, zirconium oxide, and silicon nitride.
 55. The bonded abrasiveproduct of claim 51, wherein the mean particle diameter is in a range ofbetween about 10 nm and 6 mm.
 56. The bonded abrasive product of claim51, wherein the silane components are polymerized as distincthydrophilic and hydrophobic polymers, co-polymers, or block co-polymers.57. The bonded abrasive grain of claim 51, wherein the weight ratio ofthe relatively hydrophilic silane component to the relativelyhydrophobic silane component is in a range of between about 1:99 toabout 99:1.
 58. The bonded abrasive grain of claim 51, wherein theabrasive grain is seeded sol-gel alumina grain, and the film is apolysiloxane that includes γ-methacryloxypropyltrimethoxy silane as thehydrophobic component and 3-aminopropyltriethoxysilane as thehydrophilic component.
 59. A method of making a bonded abrasive product,comprising the steps of: a) combining relatively hydrophilic andrelatively hydrophobic silane components to form a mixture; b) combiningthe mixture with a solvent to form a silane solution; c) hydrolyzing atleast a portion of the silane components to form a hydrolyzed solution;d) blending the hydrolyzed solution with an abrasive grain component toform the surface-modified abrasive grain; e) forming a green tool; andf) curing the green tool to form the bonded abrasive product.
 60. Amethod of grinding or cutting a workpiece, comprising the step ofapplying to the workpiece an abrasive product that includes apolymerized combination of relatively hydrophilic and hydrophobic silanecomponents.
 61. A surface-modified abrasive grain, comprising: a) anabrasive grain; b) a first film layer on the abrasive grain thatincludes a relatively hydrophilic silane component; and c) a second filmlayer over the first film layer that include a relatively hydrophobicsilane component.
 62. The coated abrasive of claim 61, wherein at leastone of the first and second film layers are polymerized.
 63. A coatedabrasive article, comprising: a) a backing; b) a make coat on thebacking; and c) an abrasive component at the make coat, the abrasivecomponent including an abrasive grain, a first film layer on theabrasive grain that include a relatively hydrophilic silane component,and a second film layer over the first film layer that includes arelatively hydrophobic silane component.
 64. The coated abrasive productof claim 63, wherein at least one of the first and second film layersare polymerized.
 65. A bonded abrasive product, comprising: a) a bond;and b) an abrasive component at the make coat, the abrasive componentincluding an abrasive grain, a first film layer on the abrasive grainthat includes a relatively hydrophilic silane component and a secondfilm layer over the first film layer that includes a relativelyhydrophobic silane component.
 66. The bonded abrasive of claim 65,wherein at least one of the first and second film layers arepolymerized.